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Dalton, GA. Murry Power PlantJuly, 2013Steve Davis

Case Study: Heat Recovery Steam Generator

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Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

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Customer and Case

Oglethorpe Power Corporation’s Thomas A. Smith Energy Facility in Dalton, GA was Selected as the testing platform. The plant consists of two Combined Cycle Units. Also involved in initial testing was the Electric Power Research Institute (EPRI).

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Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

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Application - Customer Motivation

Combined Cycle Power Plants consist of an initial power plant, usually a Natural Gas Fired turbine, and a Heat Recovery Steam Generator (HRSG). The HRSG uses hot exhaustgas to convert water to steam energy. This energy is used to power a steam-turbine generator.

A major problem occurs in the HRSG during hot and cold restarts. Condensation can build upin the Superheater, Reheater or Steam Headers. This condensate can cause premature tube failures, excessive down time, and lost revenue.

In order to avoid this issue, instruments are tested to detect condensate in the steam tubes before and during startup of the HRSG. The ability to detect and drain the condensate will save customers costly maintenance, degraded reliability, and excess downtime.

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Application - Measurement Point

3” 9% Chrome Alloy Steel XXS .600” wall. 680 Deg F.

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Application - Technical Details

Three different manufacturers were tested at the site: FLEXIM F601 Portable Ultrasonic Meter with Wave Injector Hi Temp Coupling GE Ultrasonic PT878 with OKS type Transducers and Waveguides MistrasTriple 5 Acoustic Sensors, PK61 and PKWD Tube Thermocouples were also used in the test A FLUKE Data Acquisition System was also utilized to collect data from all

instruments

Ultrasonic meters were used to determine sonic velocity of the medium in the pipe. Sonic velocities between 1150 and 1550 m/s signaled that water was in the pipe.Sonic velocities over 1800 m/s verified that steam was present in the pipe.

Acoustic sensors differentiated water and steam by the change in sound in the pipe. Tube Thermocouples measured temperature of the tubes. Lower temperatures

indicate water in the pipe while higher temperatures indicated steam.

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Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

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Solution - Installation

The FLEXIM was installed on Secondary (left) and Primary Superheater (right) pipes.FSP transducers and WI-400 Wave Injector were used for the test. Also, clamp on RTDs were used to monitor plate temperature of the Wave Injector.

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Solution - Results

EPRI Test Results

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Solution - Results

Signal Snap of P type transducers and Wave Injector

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Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

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Customer Benefits

The FLEXIM solution provided excellent transition results. Sonic Velocity was verified for liquid and water. A sonic velocity set point of 1550 m/s was establishedas the limit for the solid state output. This output was used to open and close drain valves.

The ability to use our non-intrusive metering, allows the customer to have confidencethat water will not be present when steam flow is initiated in the boiler. If water does appear, the FLEXIM meter will indicate this and open the drain valves without the release of live steam.

Higher availability percentage, lower maintenance costs, and less down time are the major benefits of the FLEXIM solution. FLEXIM also provides superior supportwith our Factory Trained Representatives, Regional Managers, and TechnicalSupport.